Mattress

ABSTRACT

A mattress 10 is disclosed. The mattress 10 comprises at least two laminated layers 12, 14. The at least two layers 12, 14 include a first layer 12 defining a support surface 16 configured to support a user, and a second layer 14. The first layer 12 is formed from a resiliently deformable, fluid-impervious material, and defines a plurality of perforations 18 arranged to communicate fluid through the layer 12. The second layer 14 is joined to the first layer 12 to cover an end of at least some of the perforations 18, and is formed from a fluid-pervious material. The second layer 14 is arranged to allow fluid to be communicated between at least some of the perforations 18 and a location external to the second layer 14.

TECHNICAL FIELD

The present disclosure relates generally to mattresses and, moreparticularly, relates to a mattress configured to be rolled and stored,for example, in a container.

BACKGROUND

Mattresses provide support for a user during sleep. The construction ofmattresses can vary significantly to allow the properties of themattress to be tailored to user preferences. For example, a mattress mayinclude one or more of upholstery layers, foam layers, and a cavityhousing various coil springs.

Some mattresses are constructed only from foam layers. This allows themattress to be manufactured and shipped cost-effectively, as foammaterial and manufacturing processes are low-cost, and the mattress canbe rolled and stored, for example, in a container such as a box. Themattress and box are typically configured to be lightweight and ofcompact dimensions so that a single person can handle the boxedmattress. This enhances storage, shipping and delivery.

Any discussion of documents, acts, materials, devices, articles or thelike which has been included in the present specification is not to betaken as an admission that any or all of these matters were commongeneral knowledge in the field relevant to the present disclosure as itexisted before the priority date of each of the appended claims.

SUMMARY

According to some disclosed embodiments, there is provided a mattresscomprising at least two laminated layers. The at least two layersinclude a first layer and a second layer. The first layer defines asupport surface configured to support a user, the first layer beingformed from a resiliently deformable, fluid-impervious material, andwhich defines a plurality of perforations arranged to communicate fluidthrough the layer. The second layer is joined to the first layer tocover an end of at least some of the perforations. The second layer isformed from a fluid-pervious material and arranged to allow fluid to becommunicated between the at least some of the perforations and alocation external to the second layer.

The second layer may define side-walls arranged substantiallyperpendicularly to the support surface, and be arranged to allow fluidto be communicated between the at least some of the perforations and alocation external to the side-walls.

The second layer may be at least partially surrounded by a borderarranged to at least partially define sides of the mattress, and theborder may be formed from a fluid-impervious material and define aplurality of apertures extending through the border, the apertures beingarranged to communicate fluid from the second layer to a locationexternal to the border.

The border may be formed from a material having a greater density thanthe material of the first layer. The border may be dimensioned to definea width which is greater than a thickness of the border.

The second layer may comprise two portions separated by a barrier, thebarrier being at least partially formed from a fluid-impervious materialarranged to inhibit fluid being communicated between the two portions.

The mattress may include a third layer which defines a further supportsurface configured to support the user, the third layer being formedfrom a resiliently deformable, fluid-impervious material, and defining aplurality of perforations arranged to communicate fluid through thelayer, the third layer being joined to the second layer and arranged sothat an end of at least some of the perforations of the third layer arecovered by the second layer.

The third layer may be formed from a material having a greater densitythan the material of the first layer.

The first layer and the third layer may be formed from a closed-cellfoam. The second layer may be formed from an open-cell foam.

The first layer may define a thickness which is greater than a thicknessdefined by the second layer.

The mattress may include a cover dimensioned to enclose the at least twolayers, the cover including an upper portion releasably connected to alower portion. An asymmetric seam may be defined between the upperportion and the lower portion such that at least a portion of the seamis angled towards one of the upper portion and the lower portion.

Throughout this specification the word “comprise”, or variations such as“comprises” or “comprising”, will be understood to imply the inclusionof a stated element, integer or step, or group of elements, integers orsteps, but not the exclusion of any other element, integer or step, orgroup of elements, integers or steps.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments will now be described by way of example only with referenceto the accompany drawings in which:

FIG. 1 is a perspective view of an embodiment of a mattress;

FIG. 2 is an exploded perspective view of the mattress shown in FIG. 1 ;

FIG. 3 is a plan view of the mattress shown in the previous figures;

FIG. 4 is a side view of the mattress shown in the previous figures;

FIG. 5 is an end view of the mattress shown in the previous figures;

FIG. 6 is a perspective view of the mattress shown in the previousfigures enclosed in a cover;

FIG. 7 is an exploded perspective view of the mattress and cover shownin FIG. 6 ;

FIG. 8 is an exploded perspective view of the mattress and cover shownin FIG. 7 together with a mattress topper accessory and cover extenderaccessory;

FIG. 9 is an exploded side view showing the components illustrated inFIG. 8 with the cover extender secured to a base-side portion of thecover, and showing a detailed view of a zipper for securing the coverextender to the base-side portion of the cover; and

FIG. 10 is a side view of the mattress and topper enclosed in the coverand cover extender, and showing a detailed view of a zipper for securingthe cover extender to the pillow-side portion of the cover.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

In the drawings, reference numeral 10 generally designates an embodimentof a mattress 10. The mattress 10 comprises at least two laminatedlayers 12, 14. The at least two layers 12, 14 include a first layer 12defining a support surface 16 configured to support a user, and a secondlayer 14. The first layer 12 is formed from a resiliently deformable,fluid-impervious material, and defines a plurality of perforations 18arranged to communicate fluid through the layer 12. The second layer 14is joined to the first layer 12 to cover an end of at least some of theperforations 18, and is formed from a fluid-pervious material. Thesecond layer 14 is arranged to allow fluid to be communicated between atleast some of the perforations 18 and a location external to the secondlayer 14.

In the illustrated embodiment, the mattress 10 comprises three layers12, 14, 20, where the second layer 14 is in the form of a mid-layer 14sandwiched between the first layer 12 and a third layer 20, in the formof outer layers 12, 20. It will be appreciated that the mattress 10 maycomprise more or less layers, for example, the mattress 10 may includeone or more additional fluid-permeable mid-layers. Conversely, inanother embodiment, the mattress 10 may include only a single outerlayer 12 which is joined to the second layer 14.

Each outer layer 12, 20 defines the support surface 16 which isdimensioned and arranged, in use, to support a user during sleep.Perforations 18, 22 (FIG. 2 ), being through-holes, are defined in eachsupport surface 16 and extend through the respective layer 12, 20. Inthe embodiment shown, the perforations 18, 22 extend perpendicular tothe associated support surface 16. However it will be appreciated thatthe perforations 18, 22 may be transverse to the surface 16.

Each outer layer 12, 20 is formed from a resiliently deformable,fluid-impervious material. Suitable materials include closed-cell foamssuch as latex, polyurethane and similar polymeric foams. This materialinhibits fluid, such as air and/or water, travelling through the layer12, 20. In the illustrated embodiment, the third layer 20 is formed froma polymeric foam having a greater density then a polymeric foam formingthe first layer 12. This allows the mattress 10 to be orientatedaccording to user preference for cushioning firmness, as the third layer20 provides firmer cushioning whereas the first layer 12 provides softercushioning.

The mid-layer 14 is formed from a fluid-pervious material and istypically resiliently deformable, such as an open-cell foam. Thismaterial allows fluid, such as air and/or water, to travel through thelayer 14. The mid-layer 14 is arranged to cover at least some of theperforations 18, 22 to allow fluid to be communicated between theperforations 18, 22 and a location external to the mid-layer 14. Themid-layer 14 is laminated to each of the outer layers 18, 22 so that anend of at least some of the perforations 18, 22 abuts the mid-layer 14.Lamination of the layers 12, 14, 20 generally involves application ofadhesive(s) between layers 12, 14, 20. However, additionally, oralternatively, this may involve other joining techniques, such asultrasonic welding. In some embodiments, the mid-layer 14 is only joinedto the outer layers 12, 20 around a peripheral region of the mid-layer14, for example, to reduce consumption of adhesive. In the embodimentshown, the mid-layer 14 defines a thickness (perpendicular to thesupport surface 16) which is substantially less than a thickness ofeither outer layer 12, 20 to minimise the quantity of fluid-perviousmaterial required to form the layer 14.

The mid-layer 14 includes side-walls (not visible) extendingsubstantially perpendicular to the support surface 16. The side-wallsare at least partially surrounded by a border 24 formed from afluid-impervious material. In the embodiment shown, the border 24 formsa continuous peripheral region surrounding and abutting the side-wallsof the mid-layer 14, and defines a section of each side 30 of themattress 10. The border 24 defines apertures 26 extending through theborder 24. The apertures 26 are arranged to convey fluid between theside-walls of the mid-layer 14 and a location external to the border 24,and consequently external to the mattress 10. It will be appreciatedthat in some embodiments the border 24 may be absent and, instead, themid-layer 14 is dimensioned to extend to, or near to, the sides 30, toallow fluid to directly enter and exit the side-walls of the mid-layer14.

In the illustrated embodiment, the border 24 is formed from aresiliently deformable closed-cell foam. The border 24 is dimensioned todefine a width (parallel to the support surface 16) which issubstantially greater than a thickness (perpendicular to the supportsurface 16). This arrangement and proportions enhance the border 24returning to its original shape should the mattress 10 be rolled forstorage. The foam of the border 24 has a greater density than the foamof any of the layers 12, 14, 20, and is configured to provide structurearound the periphery of the mattress 10.

The mid-layer 14 is separated into two portions 141, 142 by a barrier28. The barrier 28 is formed from a fluid-impervious material, such as aclosed cell foam, and arranged to prevent or reduce fluid beingcommunicated between the portions 141, 142. When the mattress 10 isbeing used by two users, the barrier 28 usefully prevents or reduces airand/or moisture being transferred between the portions 141, 142, therebyminimising one user disturbing the other user.

FIG. 6 shows the mattress 10 enclosed in a cover 34. The cover 34comprises two portions, being a pillow-side portion 341 and a base-sideportion or gusset 342. In the embodiment shown, the pillow-side portion341 includes padding and/or flocking, whereas the gusset 342 hasfelt-like properties. Each portion 341, 342 is formed from afluid-pervious material, such as a knitted fabric.

The portions 341, 342 are releasably joined together along a seam 36. Inthe embodiment shown the cover portions 341, 342 are releasablyconnected by a zipper extending around a periphery of the cover 34 alongthe seam 36. The seam 36 is asymmetric so that a portion 361 of the seam36 is angled towards the pillow-side portion 341. The seam 36 isarranged, in use, to be positioned along a central line extending alongeach side 30 of the mattress 10. The portion 361 of the seam 36 departsfrom this central line and is arranged, in use, extending diagonallytowards one of the support surfaces 16. This seam portion 361 allows auser to readily identify which side of the cover 34 is intended to beused as the pillow-side (with the seam portion 362 angled towards apillow end) and therefore identifies how to orientate the cover 34 foruse.

FIGS. 7 to 10 illustrate a topper accessory 38 and gusset extender 40being added to the mattress 10 to allow customising padding of auser-facing side of the mattress 10. In the embodiment shown, the topper38 is a continuous layer of material, such as a ‘memory foam’, havingspecific softness, resilience and/or thermal properties. In someembodiments (not shown), the topper 38 comprises an alternativelyconfigured padded structure, such as a quilted blanket. In otherembodiments (not shown) the topper 38 is integrally formed with thepillow-side portion 341 of the cover 34.

Best shown in FIGS. 8 and 9 , the gusset extender 40 is configured as aloop of material dimensioned to encircle the mattress 10. The gussetextender 40 has a first zipper 42 arranged along one side to allowreleasably connecting to the gusset 342, and a second zipper 44 arrangedalong an opposed side to allow releasably connecting to the pillow-sideportion 341. The gusset extender 40 is typically formed from the samematerial as the gusset 342 and effectively extends the height of thegusset 342 to increase capacity of the cover 34. This allows the cover34 to accommodate the topper 38 in addition to the mattress 10. Thewidth of the gusset extender 40, being the dimension between the opposedzippers 42, 44, is defined according to a thickness of the topper 38.

Use of the mattress 10 involves the user selecting one of the outerlayers 12, 20 according to firmness, operating the zipper to separatethe cover portions 341, 342, removing the cover 34, orientating themattress 10 so that the support surface 16 of the selected layer 12, 20faces upwards, away from a structure supporting the mattress 10, such asa bed frame, the base 32 or floor, replacing the cover 34 and operatingthe zipper to secure the cover portions 341, 342 together, with thepillow-side portion 341 facing upwards.

During sleep, as the user emits heat from their body, this causes air inthe perforations 18, 22 of the selected outer layer 12, 20 to be heatedand rise towards the user. The rising air draws cooler air through thecover 34, into the apertures 26, through the mid-layer 14 and into theperforations 18, 22. This establishes a convection current causing airto circulate beneath the user.

Many users also move whilst sleeping. Movement of the user's body causesportions of the selected layer 12, 20 to compress which forces airand/or moisture through the perforations 18, 22 towards the mid-layer14. The air and/or moisture is received in, and travels through themid-layer 14 to the border 24, where it is expelled via the apertures26, through the cover 34 and away from the mattress 10. Similarly,movement of the user's body causes portions of the selected layer 12, 20to rebound which draws air and/or moisture in the opposite route as isdescribed above.

When the mattress 10 is being used by two users simultaneously, one usermay get up from the support surface 16 and then return. When thereturning user lies on the support surface 16, air and/or moisture isforced away from the support surface 16 through the perforations 18, 22and into the mid-layer 14. In this scenario, the barrier 28 inhibits theair and/or moisture from travelling between the mid-layer portions 141,142, thereby inhibiting a sudden volume of air returning through theperforations 18, 22 of the selected layer 12, 20 and disturbing theother user.

The configuration of the perforations of the first layer 12 relative tothe fluid-permeable second layer 14 advantageously allows air and/ormoisture to be conveyed from outside of the mattress 10 towards and awayfrom the user lying on the support surface 16. This therefore ventilatesthe mattress, enhancing cooling and comfort of the user.

The border 24 arranged around the periphery of the mattress 10 usefullyprovides structural support to maintain the shape of the mattress 10.Furthermore, the configuration of the border 24 means that if themattress 10 is rolled for storage and then unpacked, the border 24reliably restores its original shape to support the sides 30 of themattress 10.

The barrier 28 arranged through the fluid-pervious second layer 14advantageously inhibits fluid being conveyed between the two secondlayer portions 141, 142 to minimise multiple users of the mattress 10disturbing each other during use.

It will be appreciated by persons skilled in the art that numerousvariations and/or modifications may be made to the above-describedembodiments, without departing from the broad general scope of thepresent disclosure. The present embodiments are, therefore, to beconsidered in all respects as illustrative and not restrictive.

1. A mattress comprising at least two laminated layers, the at least twolayers including: a first layer defining a support surface configured tosupport a user, the first layer formed from a resiliently deformable,fluid-impervious material, and defining a plurality of perforationsarranged to communicate fluid through the layer; and a second layerjoined to the first layer to cover an end of at least some of theperforations, the second layer being formed from a fluid-perviousmaterial and arranged to allow fluid to be communicated between at leastsome of the perforations and a location external to the second layer. 2.The mattress according to claim 1, wherein the second layer definesside-walls arranged substantially perpendicularly to the supportsurface, and wherein the second layer is arranged to allow fluid to becommunicated between the at least some of the perforations and alocation external to the side-walls.
 3. The mattress according to claim1, wherein the second layer is at least partially surrounded by a borderarranged to at least partially define sides of the mattress, and whereinthe border is formed from a fluid-impervious material and defines aplurality of apertures extending through the border, the apertures beingarranged to communicate fluid from the second layer to a locationexternal to the border.
 4. The mattress according to claim 3, whereinthe border is formed from a material having a greater density than thematerial of the first layer.
 5. The mattress according to claim 3,wherein the border is dimensioned to define a width which is greaterthan a thickness of the border.
 6. The mattress according to claim 1,wherein the second layer comprises two portions separated by a barrier,the barrier being at least partially formed from a fluid-imperviousmaterial arranged to inhibit fluid being communicated between the twoportions.
 7. The mattress according to claim 1 further comprising athird layer defining a further support surface configured to support theuser, the third layer formed from a resiliently deformable,fluid-impervious material, and defining a plurality of perforationsarranged to communicate fluid through the layer, the third layer beingjoined to the second layer and arranged so that an end of at least someof the perforations of the third layer are covered by the second layer.8. The mattress according to claim 7, wherein the third layer is formedfrom a material having a greater density than the material of the firstlayer.
 9. The mattress according to claim 7, wherein the first layer andthe third layer are formed from a closed-cell foam.
 10. The mattressaccording to claim 1, wherein the second layer is formed from anopen-cell foam.
 11. The mattress according to claim 1, wherein the firstlayer defines a thickness which is greater than a thickness defined bythe second layer.
 12. The mattress according to claim 1 furthercomprising a cover dimensioned to enclose the at least two layers, thecover including an upper portion releasably connected to a lowerportion.
 13. The mattress according to claim 12, wherein an asymmetricseam is defined between the upper portion and the lower portion suchthat at least a portion of the seam is angled towards one of the upperportion and the lower portion.